Orthogonal Composite Connectors for Battery Unit Assembly
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Solution Overview
Problem
The assembly and maintenance of battery units are cumbersome due to the complexity of securing main-circuit lines and communication lines, which can lead to erroneous connections and increased maintenance complexity.
Innovation Solution
The battery unit design features a housing with orthogonal composite connectors that simplify the connection of communication lines and main-circuit lines between assembled battery monitoring devices and battery management units, allowing for easy assembly and reduced error risk by using a straightforward connection pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional separate connection methods are used for main-circuit lines and communication lines, then connection flexibility is maintained, but assembly complexity increases and error risk increases
Solution Approach 1:
The patent combines the connection functions for main-circuit lines and communication lines into a single integrated connector. This connector simultaneously establishes both types of connections when components are assembled, eliminating the need for separate connection operations and reducing assembly complexity while maintaining connection flexibility.
Solution Approach 2:
The connector is designed with multi-functionality to handle both main-circuit line connections and communication line connections through a single component. This universal connector reduces the number of separate connection operations needed while maintaining the flexibility required for different connection configurations.
2Ease of repair
If multiple separate connectors are used for main-circuit lines and communication lines, then connection reliability is maintained, but maintenance complexity increases
Solution Approach 1:
By merging the connection functions into a single integrated connector, the patent simplifies maintenance operations. When maintenance is needed, technicians interact with one connector rather than multiple separate connectors, reducing the time and complexity of maintenance while the integrated design ensures both main-circuit and communication connections are maintained together, preserving reliability.
3Object-affected harmful factors
If complex routing patterns are used for lines, then connection flexibility is maintained, but noise interference increases
Solution Approach 1:
The integrated connector brings main-circuit lines and communication lines together at a single connection point, allowing for simpler, more direct routing paths. This reduces the length and complexity of line routes, thereby minimizing noise interference while the connector's design maintains the necessary connection flexibility for different configurations.
Data Source
AI summary
According to one embodiment, a unit includes battery modules each including an assembled battery including battery cells and a monitoring device, a BMU to communicate with the battery modules, a first drawer holding the battery module, a second drawer holding the BMU, and a housing containing the first drawer and the second drawer. The first and second drawers include first composite connectors secured to a side of the housing, which is almost orthogonal to a direction in which to insert the drawers into the housing. The housing has second composite connectors which mate with the first composite connectors, thereby to connect communication lines between the monitoring device and the BMU and the main-circuit lines between the assembled batteries of the battery modules.